2007 Husqvarna SM 610 / TE 610IE Factory Service & Repair Manual (P/N 8000 A7918)

• Covers 2007 Husqvarna SM 610 and TE 610 I.E. motorcycles in both 39 kW and 22 kW versions. Factory validity begins at SM 39 kW: ZCGA1AFEKP7V400000, SM 22 kW: ZCGA101AB7006000, TE 39 kW: ZCGA1EAEKP7V300000, and TE 22 kW: ZCGA101AA7006000; the factory table labels the TE entries as “TE 610 E.”
• Factory workshop publication Part No. 8000 A7918, 1st Edition (02-2007), supplied as a 503-page A4-format PDF with Italian, English, French, German, and Spanish text.
• Follows engine removal, complete internal disassembly, inspection, and reassembly of the cylinder head and valves, piston and cylinder, crankshaft and balance shaft, clutch, transmission, oil pumps, starter drive, water pump, and timing system.
• Details Marzocchi USD fork oil and seal service, air bleeding, damper teardown, rebound and compression changes, and reassembly, together with Sachs rear shock, reservoir, diaphragm, spring, swingarm, rocker, and linkage overhaul.
• Explains EFI and electrical fault isolation with wiring, connector testing, charging, starting, and ignition checks, fuel-pump and relay tests, SM/TE instrument setup, and use of Diagnosis Software Kit P/N 8000 A9634 for sensor and actuator faults plus TPS adjustment.
• Includes brake-disc and pad inspection and replacement, front and rear hydraulic bleeding, wheel and bearing work, spoke and rim checks, chain and sprocket service, steering-head adjustment, and frame alignment inspection.
• Supplies pre-delivery and periodic maintenance schedules, troubleshooting charts, torque tables, approved-fluid and capacity data, assembly clearances, wear limits, suspension settings, and electrical test specifications.

Husqvarna states that this manual was prepared for its workshops and authorized personnel. Its engine overhaul, gas-charged shock service, and EFI diagnosis sections are suited to technicians with prior motorcycle repair experience, the required measuring equipment, and access to the specified special tools.

Engine and Drivetrain Repair Depth

The single-overhead-cam, four-valve engine is handled as a full bench repair. After engine removal, the chapters separate internal disassembly, dimensional inspection, and reassembly. Coverage extends to valve seats and guides, rocker-arm bushings and cam roller, timing components, piston-to-cylinder fit, connecting-rod and crankshaft checks, clutch wear, gear-selector parts, and the dual-pump lubrication system. Reassembly addresses crankcase sealing, crankshaft and transmission installation, starter and freewheel drive, cam and balance-shaft timing, clutch setup, and final system connections.

The special-tool index identifies the crankcase puller 8000 89743, flywheel puller 8000 39523, engine holder 8000 90662, clutch-hub holding wrench 8000 39524, and TDC control tool 8000 90875. A shop can confirm tooling requirements before opening an engine repair.

SM and TE Chassis Differences

The factory validity table identifies the 39 kW and 22 kW versions by starting number, while the repair chapters use shared powertrain procedures rather than separate power-version overhauls. SM- and TE-specific material covers front-brake arrangements, wheels, final-drive chain length, fork travel and spring selection, rear-shock rebound setup, headlamp service, instrument parameters, and the SM-only tilt sensor.

The Marzocchi section includes fork troubleshooting, oil and seal replacement, air bleeding, slider and stanchion disassembly, damping-stack changes, and full assembly. The Sachs chapter carries the rear shock through spring and reservoir service, internal inspection, diaphragm replacement, oil filling and bleeding, gas charging, damping adjustment, and linkage and swingarm overhaul.

EFI, Electrical, and Illustrated References

Electrical coverage starts with the full wiring diagram and component locations, then addresses open- and short-circuit testing, meter use, generator and regulator-rectifier checks, starter and ignition inspection, battery service, lighting, switches, and harness routing. The EFI material maps the water-temperature and O2 sensors, M.A.Q.S. pressure/TPS/air-temperature unit, gear-position and battery signals, SM tilt sensor, injector, ignition coil, and O2 heater.

The manual describes current and stored fault diagnosis and separately covers fuel-pump and relay checks. It points to the diagnostic kit’s own Operation Manual for fault-memory clearing and TPS idle and feedback adjustment. The kit, interface cable, PC software, and referenced kit procedures are not included with this manual PDF.

Clearly labeled references include the main wiring diagram with cable-color key, generator test diagram, starter-relay wiring diagram, cooling-system circuit view, dual-pump lubrication schematic, and frame measurement drawing.

The manual specifically warns that substituting other compression blades in the Sachs shock can cause the shock to explode in service. It also cautions that reversed battery polarity or disconnecting a battery terminal while the engine is running can immediately damage the ECU and fuel-injection electronics. Brake bleeding, a pressurized cooling system, and gas-charged shock work require the factory safety precautions and proper workshop equipment.